Water softener regeneration control

ABSTRACT

Initiation of the regeneration cycle of a water softener is achieved on the basis of the volume of water processed by the softener. Flow volume is measured and when a preselected amount of flow has occurred, a control is actuated to initiate the regeneration cycle. The mechanism for translating the measured flow is reset to the prescribed starting point after the regeneration cycle has been initiated and is adjustable to provide control at any one of a number of different flow gallonages.

[ June 12, 1973 United States Patent 1191 Horvath [54] WATER SOFTENERREGENERATION 2,467,433 4/1949 210/190 CONTROL 3,348,005 10/1967 Mowry etal. 200/83 s 3,10l,418 8/1963 200/38 CA X John F. Horvath, Milwaukee,Wis.

[73] Assignee: Aqua-Chem, Inc., Milwaukee, Wis.

[75] Inventor:

Primary Examiner-J. R. Scott Attorney-Fred Wiviott and Ralph G.Hohenfeldt 221 Filed: Sept. 15,1971

21 Appl. No.: 180,747

[57] ABSTRACT Initiation of the regeneration cycle of a water softenerin: C1

is achieved on the basis of the volume of water processed by thesoftener. Flow volume is measured and 156 11 1 t d f 11 11 d 210/85 190w en a prese ec e amount 0 ow as occurre a control IS actuated toinitiate the regeneration cycle. The mechanism for translating themeasured flow is [51] G0ld 13/26 [58] Field ofSearch.................... 200/38 CA 200/83 S, 83 SA;

References Cited UNITED STATES PATENTS reset to the prescribed startingpoint after the regeneration cycle has been initiated and is adjustableto provide control at any one of a number of different flow 15 Claims, 3Drawing Figures g XfiXX u fi 81-.C/ l2 0 0 81 0 "B2 2 m mda awk ns r mmpo m SJKS 0027 7756 9999 111.1 [Ill 68 l 5 44 0954 p 00 4 4903 1 1 33231 WATER SOFTENER REGENERATION CONTROL BACKGROUND OF INVENTION Thisinvention relates to water softeners and, more particularly, to controlsfor initiating the regeneration cycle of a water softener.

As is well known, the resin bed of a water softener must be periodicallyregenerated. In the past, straight timing arrangements have beenutilized to initiate the regeneration cycle, i.e. after a preselectedperiod of time the regeneration cycle is initiated. Also, theregeneration cycle has also been controlled by sensors which are exposedto the water processed by the softener and respond to the ionconcentration of the water. These prior proposals have not been entirelysatisfactory. For example, those relying on a straight timing type ofoperation initiate the regeneration cycle without any real assurancethat it is taking place at the appropriate time, i.e. the regenerationmay take place before the resin bed actually needs regeneration or, onthe other hand, could be substantially late so far as the time whenregeneration is necessary. As to the arrangements for sensing directlythe water condition, these are dependent for their reliability on thecondition of the sensor itself, i.e., the sensor must be free ofcontaminants to insure accurate monitoring of the water processed by thewater softener and this is a condition difficult to maintain in theenvironment of a water softener.

This invention is concerned with this problem and has as one of itsgeneral objects to provide automatic initiation of the regenerationcycle, on a reliable basis over an extended period of time, and with aminimum of service attention.

For the achievement of this and other objects of this invention, it isproposed that an arrangement be provided wherein the volume of waterprocessed by the water softener is measured. The flow volume is utilizedas the parameter on which the initiation of the regeneration cycle isinitiated. More specifically, the metering, or measuring, mechanism isconnected through a translating mechanism to a control signal generator.The translating mechanism responds to the volume of flow measured by themetering arrangement and, when the prescribed volume of flow has beenreached, activates the control mechanism to initiate the regenerationcycle.

Preferably, adjustment is provided to vary the volume of flow which isnecessary to initiate the regeneration cycle and also provision isincluded for automatically resetting the arrangement to the desiredstarting point after the regeneration cycle has been initiated.

Other objects and advantages will be pointed out in, or be apparentfrom, the specification and claims, as will obvious modifications of thesingle embodiment shown in the drawings in which:

FIG. 1 is an exploded view of an arrangement embodying this invention;

FIG. 2 is a top plan view of the translating mechanism and the controlswitch which utilizes the regeneration cycle; and

FIG. 3 is a section view taken along line 33 of FIG. 2.

DESCRIPTION OF PREFERRED EMBODIMENT The actual showing of a watersoftener construction has been eliminated from the drawings since thewater softener per se can be of any well known structure and is notnecessary to an understanding of the present invention. It will bereadily apparent to those skilled in the art as to how the apparatusincorporating the present invention, and to be described, would beconnected into the flow system of a water softener.

With particular reference to FIG. 1, flow meter 10 is connected througha drive unit 12 to translating arrangement 14. Flow meter 10 can be ofany suitable conventional construction, for example, can be of the wellknown nutating disc type used in water meters. Also, drive 12 can be ofany conventional construction, for example that incorporating a magneticcoupling wherein the drive is powered by magnets arranged on oppositesides of imperforate wall 11 between the drive unit and the nutatingdisc chamber to insure a sealed arrangement of the meter housing. Portsl3 and 15 form the meter inlet and outlet for connection to the watersoftener. The meter can be positioned on either the untreated or softwater side of the water softener, preferably on the soft water side.

Translating arrangement 14 includes an electrical switch 16 which,through suitable electrical connections, can be connected to anarrangement (not shown) for initiating the regeneration cycle. Switch 16is utilized to provide an electrical signal to activate the watersoftener valve to interrupt the supply of soft water to the householdwhile at the same time connecting the water softener mineral tank to thebrine tank for regeneration of the resin bed. Generally the regenerationcycle is carried on in the early hours of the morning when the demandfor soft water in the household should be negligible. It is also commonpractice during this time to provide, in the water softener valve, forthe furnishing of hard water to the household so that the supply ofwater is not entirely interrupted. The water softener valve can have anywell known construction and hence has not been illustrated.

The flow gallonage measured by meter 10 is recorded in arrangement 18which includes gallonage disc 20 provided with teeth 22 which correspondto various gallonage figures. Also, disc 20 includes a plurality ofholes 24 corresponding to teeth 22 and to the various gallonage figures.A removable peg 26 is provided and can be selectively inserted intoanyone of the gallonage holes 24. The peg 26 has a projection 26a belowdisc 20 as well as above the disc as is illustrated in FIG. 3. Once theflow gallonage at which the regeneration cycle is to be initiated hasbeen determined, peg 26 can be inserted into the hole 24 whichcorresponds to that flow gallonage. Holes 24 can be provided inincrements of gallons, for example as illustrated 20 such holes areprovided and vary from 100 to 2,000 gallons.

Disc 20 fits on hub 28 and the disc and hub both fit over post 30. Nut32 and washer 34 hold the disc and hub assembled on post 30. A coilspring 36 is also mounted on post 30 and has one end 36a anchored inbase 31 with the other end 36b connected to a portion 37a of stop 37which also projects beneath disc 20 (see FIG. 3). Spring 36 is the resetspring and is arranged to return disc 20 to its initial setting afterthe regeneration cycle has been initiated. This will be explained morecompletely hereinafter. I

Pawl 38 is mounted adjacent disc 20. The pawl includes an intermediateprojection 40 and a turned end 42. Coil spring 44 extends between post43 on base 31 and post. 45 on pawl 38. The coil spring is effective tobias pawl 38 in a clockwise direction so that turned end 42 is biasedinto engagement with selective ones of teeth 22 on the disc. An arm 46is positioned beneath pawl 38 and includes a turned projection 48. Ann46 is positioned over post 56 and pawl 38 is assembled onto hub 52 andspring washer 54 is positioned between hub 52 and the upper surface ofarm 46. The assembly of arm 46, pawl 38, hub 52, and washer 54 is heldtogether on post 56 by means of nut 60 and washer 58. In the finalassembled arrangement, projection 48 on arm 46, engages the edge ofintermediate projection 40 on pawl 38 (see FIG. 2).

In operation, and as can be seen from FIG. 2, disc 20 is free to rotatein a clockwise direction. This rotation is accomplished by drive disc 64which carries a drive peg 66 arranged to engage teeth 22. In theillustrated embodiment wherein teeth 22 and holes 24 correspond to 100gallon increments, drive disc 64 rotates 360 each time 100 gallons ofwater flows through meter 10. For each full revolution of drive disc 64,peg 66 engages a successive tooth 22 on a disc 20 to step the disc onetooth. Pawl 38 is free to move in a counterclockwise direction to permitthis stepping movement but is immediately returned by spring 44, toengagement of its projection 42 with a subsequent tooth on the disc tohold a step once taken.

Peg 26 will have been positioned in the hole 24 which corresponds to thegallonage at which the regeneration cycle is intended to be initiated.The rotation of disc 20 by drive disc 64 is against the bias of resetspring 36 so that as the disc is being driven through the various steps,a spring force is built up in the reset spring tending to rotate thedisc in a counter-clockwise direction. When drive disc 64 moves disc 20through the last step to the prescribed gallonage, the projection 26a ofpeg 26 beneath disc 20 will engage turned portion 48 on arm 46 so thatduring this last step arm 46 will be driven in a counter-clockwisedirection with arm 46 engaging switch lever 62 to activate switch 16 andinitiate the regeneration cycle. Because of the engagement betweenturned portion 48 and intermediate projection 40 on pawl 38, pawl 38will also be driven in a counterclockwise direction, thereby freeingdisc 20 for movement in a counter-clockwise direction so that it may bereturned to its initial setting position. Stop 37 limits the movement ofthe disc 20 in the resetting direction by engagement with anothersuitably arranged stop (not shown). The reset or counter-clockwiserotation of disc 20, is achieved by reset spring 36. It will beappreciated that spring 36 is effective to return to disc 20 to thereset position before spring 44 is capable of returning pawl 38 to itsposition in engagement with teeth 22. Movement of peg 26 on disc 20 isalso relative to arm 46 and thus will vary the amount of movement ofdisc 20 which is necessary before arm 46 is engaged and moved to operateswitch 62.

Accordingly, a relatively simple control arrangement is provided whichachieves initiation of the regeneration cycle on the basis of flowgallonage through the water softener. The control is adjustable toselect that gallonage which has been determined, with experience withthe particular water source involved, to require regeneration. Thecontrol automatically resets itself at a zero setting position sothat'the water softener can then return to a normal cycling and willagain monitor flow to initiate the regeneration cycle when necessary.

It will also be appreciated that switch 16 can be connected to asuitable timing mechanism, rather than dihas been reached so that theregeneration cycle does not occur during normal household water usagehours.

Although but one embodiment of the present invention has beenillustrated and described, it will be apparent to those skilled in theart that various changes and modifications may be made therein withoutdeparting from the spirit of the invention or from the scope of theappended claims.

I claim:

1. An arrangement for initiating the regeneration cycle of a watersoftener and comprising, in combination,

flow metering means having input and output means and responsive to thevolume of a fluid medium flowing between said input and output means,flow directing means for coupling said input and output means in aseries relation with a water softener and operative to direct the flowof said medium which occurs through said water softener through saidmetering means input and output, control signal generating meansoperative to provide a regenerating cycle initiating signal, andtranslating means connected to said metering means and operativelyassociated with said control signal generating means, said meteringmeans being operative to actuate said translating means when apreselected volume of fluid medium has passed through said watersoftener, said translating means being operative when actuated toactivate said control signal generating means. 2. The arrangement ofclaim 1 wherein said translating means includes means for adjusting thepreselected volume at which said translating means activates saidcontrol signal generating means.

3. The arrangement of claim 1 wherein said translating means includes afirst movable member,

a second movable member supported for movement relative to said firstmovable member,

means connecting said second movable member to said metering means formovement thereof relative to said first movable member on the basis ofvolume flow,

said second movable member including means for adjusting the amount ofrelative movement between said first and second movable members beforesaid second movable member engages and moves said first movable memberso that the volume of flow necessary to engage said first and secondmovable members can be varied,

and said control signal generating means engageable with and activatedby said first movable member when said first movable member is engagedand moved by said second movable member.

4. The arrangement of claim 3 including reset means connected to saidsecond movable member and operative when said first movable member hasengaged and activated said control signal generating means to returnsaid second movable member to its initial starting point relative tosaid first movable member.

5. The arrangement of claim 4 wherein said reset means includes biasingmeans connected to said second movable member and opposing movementthereof in response to increased flow of gallonage and biasing saidsecond movable member in a direction toward its initial startingposition.

6. The arrangement of claim 1 wherein said translating means includes adisc member including means defining a plurality of holes and teethcorresponding to different amounts of flow gallonage,

a drive member connected to said metering means and selectively engagingand moving said disc member in a stepped rotation manner correspondingto a preselected gallonage figure each time said metering means measuressaid preselected gallonage figure,

a pawl adjacent to said disc and selectively engageable with the teeththereof to hold said disc in 'a stepped position,

an operating arm engaging said pawl and mounted for engagement by saiddisc as said disc rotates in response to increase flow gallonage,

and means on said disc adjustably positioned in a selective one of saidholes and engageable with said operating arm to pivot that arm when thepreselected volume gallonage has been' reached,

and switch means associated with and engageable by said operating armwhen said arm is engaged and pivoted by said adjustable means on saiddisc, said switch means being effective to initiate said regenerationcycle when engaged by said arm.

7. The arrangement of claim 6 including spring means connected to saiddisc and opposing rtation thereof in response to increased gallonageflow,

and said arm engaging said pawl and moving said pawl out of engagementwith said disc when said arm is moved by said adjustable means on saiddisc to engage said switch means so that said spring means returns saiddisc to the initial setting thereof.

8. Apparatus for providing a control signal based on flow volume andcomprising, in combination,

flow metering means having input and output means and operative toperform a control function in response to the flow of a predeterminedvolume of a fluid medium between said input and output means,

flow directing means for connecting said input and output means inseries with the flow path of the medium being measured,

control signal generating means operatively associated with saidmetering means, and

translating means connected to said metering means and operativelyassociated with said control signal generating means and responsive tothe control function of said metering means to activate the controlsignal generating means when a preselected volume of fluid medium haspassed through said metering means.

9. The arrangement of claim 8 wherein said translating means includesmeans for adjusting the preselected volume at which said translatingmeans activates said control signal generating means.

10. The arrangement of claim 8 wherein said translating means includes afirst movable member,

a second movable member supported for movement relative to said firstmovable member,

means connecting said second movable member to said metering means formovement thereof relative to said first movable member on the basis ofvolume flow, said second movable member including means for adjustingthe amount of relative movement between said first and second movablemembers before said second movable member engages and moves said firstmovable member so that the volume of flow necessary to engage said firstand second movable members can be varied,

and said control signal generating means engageable with and activatedby said first movable member when said first movable member is engagedand moved by said second movable member.

1 1. The arrangement of claim 8 wherein said translating means includesa disc member including means defining a plurality of holes and teethcorresponding to different amounts of flow gallonage,

a drive member connected to said metering means and selectively engagingand moving said disc member in a stepped rotation manner correspondingto a preselected gallonage figure each time said metering means measuressaid preselected gallonage figure,

a pawl adjacent to said disc and selectively engageable with the teeththereof to hold said disc in a stepped position,

an operating arm engaging said pawl and mounted for engagement by saiddisc as said disc rotates in response to continued flow gallonage,

and means on said disc adjustably positioned in a selective one of saidholes and engageable with said operating arm to pivot that arm when thepreselected volume gallonage has been reached,

and switch means associated with and engageable by said operating armwhen said arm is engaged and pivoted by said adjustable means on saiddisc, said switch being effective to initiate said regeneration cyclewhen engaged by said arm.

12. The arrangement of claim 11 including spring means connected to saiddisc and opposing rotation thereof in response to increased gallonageflow,

and said arm engaging said pawl and moving said pawl out of engagementwith said disc when said arm is moved by said adjustable means on saiddisc to engage said switch means so that said spring means returns saiddisc to the initial setting thereof.

13. An arrangement for initiating the regeneration cycle of a watersoftener and comprising, in combination,

metering means having input and output means and operative to perform acontrol function in response to the flow of a predetermined volume of afluid medium,

flow directing means for coupling said input and output means in aseries relation to a water softener and operative to direct the flow ofsaid medium through both said water softener and metering means, v

control signal generating means operatively associated with saidmetering means,

said metering means being operative in response to said control functionto actuate said signal generating means when a preselected volume of afluid medium has passed through said water softener, said control signalgenerating means being operative said translating means includes anelement, said metering means being operative to progressively advancesaid element from a first position to a second position in response tovolumetric flow, said element being operative when in said secondposition to actuate said control signal generating means, and

means for adjusting the initial position of said element.

a u w w

1. An arrangement for initiating the regeneration cycle of a watersoftener and comprising, in combination, flow metering means havinginput and output means and responsive to the volume of a fluid mediumflowing between said input and output means, flow directing means forcoupling said input and output means in a series relation with a watersoftener and operative to direct the flow of said medium which occursthrough said water softener through said metering means input andoutput, control signal generating means operative to provide aregenerating cycle initiating signal, and translating means connected tosaid metering means and operatively associated with said control signalgenerating means, said metering means being operative to actuate saidtranslating means when a preselected volume of fluid medium has passedthrough said water softener, said translating means being operative whenactuated to activate said control signal generating means.
 2. Thearrangement of claim 1 wherein said translating means includes means foradjusting the preselected volume at which said translating meansactivates said control signal generating means.
 3. The arrangement ofclaim 1 wherein said translating means includes a first movable member,a second movable member supported for movement relative to said firstmovable member, means connecting said second movable member to saidmetering means for movement thereof relative to said first movablemember on the basis of volume flow, said second movable member includingmeans for adjusting the amount of relative movement between said firstand second movable members before said second movable member engages andmoves said first movable member so that the volume of flow necessary toengage said first and second movable members can be varied, and saidcontrol signal generating means engageable with and activated by saidfirst movable member when said first movable member is engaged and movedby said second movable member.
 4. The arrangement of claim 3 includingreset means connected to said second movable member and operative whensaid first movable member has engaged and activated said control signalgenerating means to return said second movable member to its initialstarting point relative to said first movable member.
 5. The arrangementof claim 4 wherein said reset means includes biasing means connected tosaid second movable member and opposing movement thereof in response toincreased flow of gallonage and biasing said second movable member in adirection toward its initial starting position.
 6. The arrangement ofclaim 1 wherein said translating means includes a disc member includingmeans defining a plurality of holes and teeth corresponding to differentamounts of flow gallonage, a drive member connected to said meteringmeans and selectively engaging and moving said disc member in a steppedrotation manner corresponding to a preselected gallonage figure eachtime said metering means measures said preselected gallonage figure, apawl adjacent to said disc and selectively engageable with the teeththereof to hold said disc in a stepped position, an operating armengaging said pawl and mounted for engagement by said disc as said discrotates in response to increase flow gallonage, and means on said discadjustably positioned in a selective one of said holes and engageablewith said operating arm to pivot that arm when the preselected volumegallonage has been reached, and switch means associated with andengageable by said operating arm when said arm is engaged and pivoted bysaid adjustable means on said disc, said switch means being effective toinitiate said regeneration cycle when engaged by said arm.
 7. Thearrangement of claim 6 including spring means connected to said disc andopposing rotation theReof in response to increased gallonage flow, andsaid arm engaging said pawl and moving said pawl out of engagement withsaid disc when said arm is moved by said adjustable means on said discto engage said switch means so that said spring means returns said discto the initial setting thereof.
 8. Apparatus for providing a controlsignal based on flow volume and comprising, in combination, flowmetering means having input and output means and operative to perform acontrol function in response to the flow of a predetermined volume of afluid medium between said input and output means, flow directing meansfor connecting said input and output means in series with the flow pathof the medium being measured, control signal generating meansoperatively associated with said metering means, and translating meansconnected to said metering means and operatively associated with saidcontrol signal generating means and responsive to the control functionof said metering means to activate the control signal generating meanswhen a preselected volume of fluid medium has passed through saidmetering means.
 9. The arrangement of claim 8 wherein said translatingmeans includes means for adjusting the preselected volume at which saidtranslating means activates said control signal generating means. 10.The arrangement of claim 8 wherein said translating means includes afirst movable member, a second movable member supported for movementrelative to said first movable member, means connecting said secondmovable member to said metering means for movement thereof relative tosaid first movable member on the basis of volume flow, said secondmovable member including means for adjusting the amount of relativemovement between said first and second movable members before saidsecond movable member engages and moves said first movable member sothat the volume of flow necessary to engage said first and secondmovable members can be varied, and said control signal generating meansengageable with and activated by said first movable member when saidfirst movable member is engaged and moved by said second movable member.11. The arrangement of claim 8 wherein said translating means includes adisc member including means defining a plurality of holes and teethcorresponding to different amounts of flow gallonage, a drive memberconnected to said metering means and selectively engaging and movingsaid disc member in a stepped rotation manner corresponding to apreselected gallonage figure each time said metering means measures saidpreselected gallonage figure, a pawl adjacent to said disc andselectively engageable with the teeth thereof to hold said disc in astepped position, an operating arm engaging said pawl and mounted forengagement by said disc as said disc rotates in response to continuedflow gallonage, and means on said disc adjustably positioned in aselective one of said holes and engageable with said operating arm topivot that arm when the preselected volume gallonage has been reached,and switch means associated with and engageable by said operating armwhen said arm is engaged and pivoted by said adjustable means on saiddisc, said switch being effective to initiate said regeneration cyclewhen engaged by said arm.
 12. The arrangement of claim 11 includingspring means connected to said disc and opposing rotation thereof inresponse to increased gallonage flow, and said arm engaging said pawland moving said pawl out of engagement with said disc when said arm ismoved by said adjustable means on said disc to engage said switch meansso that said spring means returns said disc to the initial settingthereof.
 13. An arrangement for initiating the regeneration cycle of awater softener and comprising, in combination, metering means havinginput and output means and operative to perform a control function inresponse to the flow of a predetermined volume of a fluid medium, flowdirecting means for coupling said input and output means in a seriesrelation to a water softener and operative to direct the flow of saidmedium through both said water softener and metering means, controlsignal generating means operatively associated with said metering means,said metering means being operative in response to said control functionto actuate said signal generating means when a preselected volume of afluid medium has passed through said water softener, said control signalgenerating means being operative when actuated to generate aregeneration cycle initiating signal.
 14. The arrangement of claim 13wherein said metering means includes translating means for actuatingsaid control signal generating means and adjusting means for adjustingthe preselected volume at which said translating means activates saidcontrol signal generating means.
 15. The arrangement set forth in claim14 wherein said translating means includes an element, said meteringmeans being operative to progressively advance said element from a firstposition to a second position in response to volumetric flow, saidelement being operative when in said second position to actuate saidcontrol signal generating means, and means for adjusting the initialposition of said element.